Schaeffler SpindleSense · Features Schaeffler SpindleSense is a compact measuring system for use in machine tools, which allows non-contact and high-precision measurement of the

Schaeffler SpindleSenseSpindle monitoring by measuring displacement

Foreword

The machine building and equipment production sector is charac-terised by the trend towards intelligent, networked machines.It is becoming increasingly important to gain information aboutthe operating mode of machinery. Wherever machine components move, there is a need for data on measurement values such as velocity, speed, force or temperature. The bearing position is often the ideal location for collecting these data. The high precisionof rolling bearings and the accuracy of the adjacent construction facilitate high quality of measurement at this point.Identifying critical machine conditions in good time is extremely important, particularly in machine tools. In addition to this,the captured process data help to optimise the production process further.With Schaeffler SpindleSense, Schaeffler offers a very compact solution for main spindles and thus enables displacement measure-ment, which can be used in applications ranging from process monitoring through to the implementation of a closed-loop process control system. In addition, Schaeffler SpindleSense containsan integrated evaluation unit, which in combination with FAG spindle bearings and following adaptation of the evaluation algorithmto the spindle and machine, permits reporting of an overload onthe spindle bearing arrangement.

Current product informationalways online

This edition of this publication describes the status of product information at the time of publication.The current edition of TPI 258 is already available for download at:■ www.schaeffler.de/std/1F33.

2 TPI 258 Schaeffler Technologies

Schaeffler Technologies TPI 258 3

Page

Contents

Features Design...................................................................................... 4

Measurement principle ............................................................. 5

Functional scope ...................................................................... 5

Interfaces ................................................................................. 6

Operating life............................................................................ 7

Ordering designation ................................................................ 8

Design andsafety guidelines

Design of the bearing position................................................... 9Tolerances ........................................................................... 9Stationary outer ring............................................................. 9Arrangement ........................................................................ 10Designed to be easily dismantled ......................................... 10

Connection ............................................................................... 11

Voltage supply.......................................................................... 12

Electromagnetic compatibility ................................................... 12

Permissible indirect process materials ...................................... 12

Operating limits ........................................................................ 13Exclusion criteria.................................................................. 13Ambient conditions .............................................................. 13

Dimension table Schaeffler SpindleSense ........................................................... 14

Appendix Request form


Schaeffler SpindleSense

Features Schaeffler SpindleSense is a compact measuring system for usein machine tools, which allows non-contact and high-precision measurement of the displacement between shaft and housingwith high measurement frequency.When used in combination with FAG spindle bearings, it is also possible to detect overloads. As a result, damage and resulting machine downtimes can be avoided.

Design The sensor unit comprises a sensor ring and both an axial anda radial measurement ring.

The sensor ring has the following integral components:■ 3 axially and 3 radially arranged eddy current distance sensors■ Evaluation unit (hardware and software)■ Connection cable for data exchange and voltage supply.

Materials

� Sensor unit

Sensor unit components:� Sensor ring

� Radial measurement ring� Axial measurement ring

Figure 1Sensor unit

1

2

34

0010

AB26

0010

AB26

� Eddy current distance sensors� Evaluation unit

� Connection cable

Figure 2Sensor ring

(image without module support andwithout cast material)

11

1

3

2

0010

ABC5

0010

ABC5

Components Material

Sensor ring, measurement rings 100Cr6

Cast material Epoxy resin

Cable sheath for connection cable Polyurethane


Measurement principle The distance sensors measure the axial and radial displacement between the sensor ring fixed in the housing and the measurement rings located on the shaft with a resolution of approximately 1 �m. The displacements and tilting determined by this method are out-putted at a frequency of 1 kHz via CAN bus.With appropriate parametrising, the evaluation unit integrated inthe sensor ring also calculates the load on the bearing. For this pur-pose, the speed signal of the spindle must also be fed to the sensor ring. The evaluation unit then identifies critical conditions within 2 ms and sends these to the machine controller via the CAN bus and digital signal output.

The displacement is caused by axial loading, radial loading, tilting and temperature. These influences must be taken into consideration in the interpretation of the measurement results.To ensure the displacement measurement is interpreted correctly,it is essential that Schaeffler carry out a comprehensive analysis of the application.

Functional scope Schaeffler SpindleSense is supplied as standard in a basic version with displacement measurement (functional scope: C-A1).When used in combination with FAG spindle bearings, the function can be expanded to detect overloading of the spindle bearings.This requires an application-specific configuration of the sensor ring by Schaeffler.

Functional scope

The functional scope is part of the ordering designation, see page 8.

� Housing� Shaft

� Bearing� Sensor ring

� Axial measurement ring� Radial measurement ring

Figure 3Displacement measurement

1

2

3 3 45

6

0016

A109

0016

A109

Designation Description

C-A1 Output for measured displacements (axial and radial) and tilting via CAN bus

Upgrade Alarm message output, if limiting values for load orkinematics are exceeded



Interfaces Schaeffler SpindleSense has the interfaces shown in Figure 4, Figure 5 and table: ■ CAN bus as communications interface between the sensor ring

and Windows PC and for the output of measurement data for further processing. Configuration software provides comprehen-sive setting options and allows software updates

■ voltage supply■ alarm and error output■ speed signal inputs (HTL compatible).

Figure 4Interfaces

(functional scope: C-A1)

+–+

–

Voltage supplyDC 24 V

USB

CAN

PWR

CAN-USB-adapter Setup Service Tool

(commissioning and service)

Windows SoftwareSchaefflerSpindleSense

sensor ring

(operation)

Processing ofmeasurement data

0017

291A

0017

291A

Figure 5Interfaces

(functional scope: C-A1 + upgrade)

+–+

–


sensor ring

Error, alarm

USB

CAN

PWR

D-Out

D-In

CAN-USB-adapter

Speed

Windows SoftwareSetup Service Tool(commissioning and service)

Voltage supply

NC (Numeric Control)

(operation)

DC 24 V

Alarm messages to machinecontroller due to overloadon spindle bearing

Speed signal as inputvalue for signal assessmentin sensor ring

Processing ofmeasurement data

0016

BA0C

0016

BA0C


Interface characteristics

1) Minimum duration = 50 ms.During this time there is no signal output via the CAN bus.

Operating life Schaeffler SpindleSense has a documented operating life of 18 000 hours.The operating life was determined for a specific temperature spectrum, see table.

Temperature spectrum

Name Characteristic

CAN CAN bus

Symbol rate 1 MBd (high-speed CAN)

Protocol Proprietary

PWR Voltage supply DC 24 V, see table, page 12

D-Out Digital output

Output voltage (signal type)

normal operation 24 V (constant)

alarm (overload) 0 V (constant)

error 0 V up to 24 V(square wave signal, 1 Hz)

Output voltage (duration)

normal operation Continuous

alarm (overload) Configurable

error For as long as the error remains1)

Output current permanent 50 mA

maximum 100 mA

D-In Digital input

Signal type Speed (HTL compatible)

Signal voltage 0 V up to 24 V(square wave signal)

Temperature Time proportion of the operating life test

°C %

0 1

+23 20

+40 69

+75 9

+80 1



Ordering designation The structure of the ordering designation is shown in Figure 6.

Figure 6Ordering designation

SRS

16

101

A

SRS70x100x16-A-1-101

1 C-A1

70incl.100

100incl.150

Generation

Sensor unit (sensor ring withmeasurement rings)

Type

Inside diameterof the sensor unit

Inside diameter

Outside diameterof the sensor unit

Outside diameter

Width of the sensor unit

Width

Functional scope

CAN bus

Configuration

Generation A, from July 2019

0018

B3EC

0018

B3EC


Design andsafety guidelines

Design of the bearing position Schaeffler SpindleSense is installed in the immediate vicinityof Schaeffler spindle bearings. The requirements for the mounting position depend on the spindle bearing requirements.

Tolerances The required machining tolerances for the shaft and housing when fitting Schaeffler SpindleSense are exactly the same as those required for the spindle bearings.Note on Schaeffler SpindleSense tolerances:■ The tolerances for the sensor rings, the axial measurement

rings and the radial measurement rings are based onthe Schaeffler intermediate ring tolerances with the exception of the bore tolerances for the radial measurement rings.

■ The radial measurement ring bore tolerances are based onthe Schaeffler spindle bearing bore tolerances.

For more information on the tolerances for Schaeffler SpindleSense, see dimension table.

Further information Tables with shaft and housing machining tolerances as well astables with tolerances for Schaeffler spindle bearings and Schaeffler intermediate rings can be found in:■ Catalogue SP 1, Super Precision Bearings.

Stationary outer ring Schaeffler SpindleSense can only be used in applications witha stationary outer ring due to the cable connection arrangement.An anti-rotation locking device is not required. The sensor ring is secured against rotation by the axial bracing.



Arrangement The preferred installation position for Schaeffler SpindleSense is directly in front of the first bearing on the work side of the spindle, between the bearing and the tool interface, Figure 7.Due to the extremely small distance between the sensor ring andthe bearing, this arrangement leads to maximum accuracy when measuring the displacement and the subsequent calculation ofthe load on the bearing.

For bearings with pneumatic oil lubrication, we recommend an intermediate ring through which the oil can pass.Lubricants and coolants should not be guided through the gap between the sensor ring and the measurement rings on Schaeffler SpindleSense.We recommend the cable is guided to the outside through the gap between the housing and the cover, Figure 7.

Designed to be easily dismantled The construction is to be designed such that it is possible to dismantle the sensor ring and the measurement rings without any forces being transmitted through the casting for the sensor ring’s electronics. The dismantling forces can be transmitted throughthe steel ring on the sensor ring.Transmitting the dismantling forces through the castingfor the sensor ring’s electronics can damage the electronics.

� Shaft� Housing

� Housing cover� Sensor ring

� Radial measurement ring� Axial measurement ring

� Bearing

Figure 7Arrangement

1

2

4 7

65

3

0010

AB44

0010

AB44


Connection Schaeffler SpindleSense is supplied with a 6-pole, 2 m long connec-tion cable which is not suitable for drag chain use, Figure 8.Once the cable has been fitted into the spindle, it can be shortened to the required length.The cable has a temporary connector for easy initial configuration and protection of the cords during transport. This connector should be removed and replaced with a suitable connector.The cable outlet is designed such that the cable can be guided away from the sensor ring in an axial or radial direction.

The connection cable is designed with as small a cross section as possible so that it occupies the minimum amount of space once in place, see tables, page 11 and page 12.

Connection cableTechnical data

� Sensor ring� Cable outlet,axial and radial

� Connection cable� Temporary connector and

transport protection(to be removed)

Figure 8Sensor ring with connection cable

1

2

3

4

0016

5DF6

0016

5DF6

Designation Value

Type Shielded sensor cable

Length 2 m

Cross-section area of conductor 6�0,093 mm2

Outside diameter 3,8 mm �0,15 mm

Minimum bending radius static 7,4 mm(2 times the outside diameter)

dynamic 19 mm(5 times the outside diameter)

Recommended bending radius dynamic 38 mm(10 times the outside diameter)

Temperature range static –40 °C up to +80 °C

dynamic 0 °C up to +80 °C

Mass 23 g/m

Material (cable sheath) Polyurethane



Connection cableSignal assignment of the cables

Voltage supply In addition to the internal fuse, an external fuse is requiredon the customer side for the voltage supply of the sensor unit,see table.

Voltage supply and fuse

Electromagnetic compatibility In order to ensure electromagnetic compatibility, the connection cable is shielded.

Further information Further information on electromagnetic compatibility and shielding:■ BA 61, Schaeffler SpindleSense – user manual.

Permissible indirect processmaterials

The resistance of the encapsulating material used in the sensor ring has been checked and confirmed for a selection of indirect process materials.

Indirect process materials to whichthe sensor unit is resistant

Signal Cable

Colour Number

Voltage supply Grey 1

Ground Brown 2

Digital output overload Pink 3

Digital input speed White 4

CAN low Yellow 5

CAN high Green 6

Shielding – –

Designation Value

Supply voltage nominal DC 24 V

tolerance �4%

Power consumption typical 60 mA at 24 V

max. 100 mA at 24 V

Switch-on current 1,2 A

Internal fuse self-resetting

typical operation 200 mA

trip 500 mA up to 600 mA

External fuse required, to be fitted by the customer

Type Designation

Mounting paste FAG ARCANOL-MOUNTINGPASTE

Oil for gearboxes and rolling bearings Mobil SHC 626

Oil for gearboxes OEST SYNTH SAE 75W-90

ASTM reference oil IRM 902

Cooling lubricant Emulcut 4020 (5%)

Castrol Syntilo 81BF (5%)


Operating limits Schaeffler SpindleSense is intended for use with machine tool spindles where there are no special protection requirements.The exclusion criteria and ambient conditions stated below must be observed.

Exclusion criteria Schaeffler SpindleSense may not be used in the following application areas:■ explosive environments (ATEX)■ nuclear power■ aerospace■ rail■ military■ medical equipment.In addition to the areas of application that are explicitly excluded, Schaeffler SpindleSense may also not be used in any applications where the use of the measurement values has an influence onthe safety of the machine itself, any adjacent systems, or people.

Ambient conditions Air pressure:■ The permissible ambient pressure range is

700 hPa up to 1050 hPa.Temperature:■ The permissible ambient temperature range is

0 °C up to 80 °C.Protection type in accordance with ISO 20653:■ The sensor and interface unit are designed in accordance

with the protection type IP65.Excluded ambient conditions:■ Magnetically or electrically conductive dusts or particles.



Sensor ring Cable outlet

Bs

tsts

Bs1

rsrs

Ds Ds2 Ds1ds

0016

4955

0016

4955 Bs2

0016

1E9B

0016

1E9B

Dimension table · Dimensions in mm

Designation Mass Dimensions

Sensor ring

for spindle bearings m ds Ds Bs Bs1 rs Ds1 Ds2

Series 719 Series 70 � kg min.

SRS70X100X16-A – 0,45 76,4 100 –0,012–0,034 16 0

–0,1 12,5 +0,1–0,4 1 94,65 92,4

– SRS70X110X16-A 0,65 76,4 110 –0,012–0,034 16 0

–0,1 12,5 +0,1–0,4 1,1 102,15 102,15

SRS80X110X16-A – 0,55 86,7 110 –0,012–0,034 16 0

–0,1 12,5 +0,1–0,4 1 104,15 102,7

– SRS80X125X16-A 0,87 86,7 125 –0,014–0,039 16 0

–0,1 12,5 +0,1–0,4 1,1 117,15 117,15

SRS100X140X16-A – 0,89 110,8 140 –0,014–0,039 16 0

–0,1 12,5 +0,1–0,4 1,1 133,2 133,2

– SRS100X150X16-A 0,9 110,8 150 –0,014–0,039 16 0

–0,1 12,5 +0,1–0,4 1,5 141,2 141,2


Measurement rings

Bax

Dax daxBr

Drdr

0016

5C5B

0016

5C5B

Mounting dimensions

Da

Da

da

ra

ra

ra1

ra1

da

0017

2155

0017

2155

Axial measurement ring Radial measurement ring Mounting dimensions

ts Bs2 dax Dax Bax dr Dr Br da Da ra ra1

h12 H12 max. max.

0,5 6,5 70 +0,04+0,03 91,6 3 0

–0,05 70 0–0,007 75,6 13 0

–0,05 76 94,5 0,3 1,9

0,5 6,5 70 +0,04+0,03 91,6 3 0

–0,05 70 0–0,007 75,6 13 0

–0,05 77 102 0,3 2

0,5 6,5 80 +0,04+0,03 101,9 3 0

–0,05 80 0–0,007 85,9 13 0

–0,05 86 104 0,3 1,9

0,5 6,5 80 +0,04+0,03 101,9 3 0

–0,05 80 0–0,007 85,9 13 0

–0,05 88 117 0,3 2

0,5 6,5 100 +0,04+0,03 128 3 0

–0,05 100 0–0,008 110 13 0

–0,05 107 133 0,3 2

0,5 6,5 100 +0,04+0,03 128 3 0

–0,05 100 0–0,008 110 13 0

–0,05 110 141 0,3 2,3


Request for parametrisation of Schaeffler SpindleSense

Schaeffler Technologies AG & Co. KG Georg-Schäfer-Strasse 30 · 97421 Schweinfurt · Germany · www.schaeffler.de · [email protected]

Customer:

Contact:

Machine type: Drive system: Application objective:❑ Car production ❑ Motor spindle, direct drive ❑ Overload detection❑ Tooling and mould production ❑ Belt drive ❑ Displacement measurement❑ Universal machine ❑ Threaded spindle ❑ Displacement compensation❑ High-performance milling,

turning and grinding❑ Inline spindle ❑ Monitoring of bearing load

❑ High-speed machining

Drawing attached: ❑ yes Bearing arrangement (diagram, for example �� ):❑ no

Shaft position: ❑ rigid❑ vertical ❑ spring-adjusted❑ horizontal Spring force❑ swivelling

Spring rigidity

Bearing type(s) working side (front):

working side (rear):

Bearing diameter, working side inside: mm

outside: mm

Maximum speed: min–1

Lubrication:

Nominal viscosity: mm2 · s–1

Load cyclesForces Speed Time portion Tool diameter Boom Belt tension,

driveFr Fa Ft a FR

kN kN kN min–1 % mm mm kN


Special environmental influences, operating conditions:

Assumptions:

Bearing operating temperature front, rear: T = , °C

�T (inner ring/outer ring) front, rear: , K

Interference (shaft/inner ring) front, rear: , �m

Clearance fit (outer ring/housing) front, rear: , �m

Bearing spacing l: mm

lB: mm

Drive spacing b: mm

Boom a: mm, see table

Installation direction: ❑ Variant 1 ❑ Variant 2

lalB

b

di1 = ________ mm di2 = ________ mm

Fr FRTAR = _____°C

TIR = _____°CFa

0016

C264

0016

C264

lB

0016

C273

0016

C273

lB00

16C2

7400

16C2

74

Anticipated quantity per year:

Questions(please attach drawings if possible):

Contact: Date:

Please send the completed form to [email protected]

Schaeffler TechnologiesAG & Co. KG

Georg-Schäfer-Straße 3097421 SchweinfurtGermanyInternet www.schaeffler.de/enE-mail [email protected]

In Germany:Phone 0180 5003872Fax 0180 5003873

From other countries:Phone +49 9721 91-0Fax +49 9721 91-3435

Every care has been taken to ensure the

correctness of the information contained

in this publication but no liability can

be accepted for any errors or omissions.

We reserve the right to make technical

changes.

© Schaeffler Technologies AG & Co. KG

Issued: 2020, September

This publication or parts thereof may not

be reproduced without our permission.

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Documents

Schaeffler SpindleSense · Features Schaeffler SpindleSense is a compact measuring system for use in machine tools, which allows non-contact and high-precision measurement of the